Where does the wire harness for the driver's side headlight course thru and is it easy to do?

4SCHNEIDERS

MEMBER
2007 FORD FUSION
68,000 MILES

The male end to the headlight charred and burned at the headlamp female connection. I cut it off and spliced in a new male end. This lasted 6 months and now the weatherproof quick splice has lost contact and the light goes on and off as I pull on the splice area. I need to just replace the wire harness to the headlight. Is it easy to do? What will I need to do the job? Is there a UTUBE video I could watch? Your help is appreciated. Sometimes I know just enough to be dangerous.

1 Reply

DRCRANKNWRENCH

MECHANIC
3,380 POSTS

It all depends on how far you have to run the harness. It does not sound like you have to go through any thing like the firewall which can be difficult and many times will short the wires as without the proper protection the wires will lose their insulation rubing against the edge of the firewall passage. That is the type of thing to keep in mind as you run the wiores. Is there anything that could damage wire insulation and short out wires in the area where they will be run? If so, then you need to buy some wire protection such as plastic conduit which you can find at most auto parts stores. The other things to keep in mind is not to use connecters everywhere and instead mayke sure you splicae and sauder the wires where they were a continuous wire before. The use of extra connectors will increase resistance in the wires and the headlight night not be as bright as the other one. You oust also use the same gauge size wire as the wire that is still remaining from burnt circuit. If you use wire that is too small, it will heat up and cause the type of situation that caused this problem in the first place. So make sure the wire you use is the same ssize as what you have spliced into.
Other than those issues you are simply filling back in the wires that were damaged. Making sure that they are the correct wire size and protecting them from damage are the only real concerns.